Nonlinear optimization of steel production using traditional and novel blast furnace operation strategies

Helle, Hannu; Helle, Mikko; Saxén, Henrik

doi:10.1016/j.ces.2011.09.006

Cited by 52 publications

(34 citation statements)

References 26 publications

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“…The core of the mathematical description of the steel plant is the blast furnace model, which is described in detail in the Appendix of Helle et al 17) It implements the basic features of the operation diagram introduced by Rist and co-workers. 18) It applies a division of the process into two main control volumes, an upper preparation zone and a lower elaboration zone, separated by reserve zone where the temperatures of solids and gas are (almost) equal and known, and the gas composition can be calculated from an approach to equilibrium.…”

Section: Process Modelsmentioning

confidence: 99%

Optimization of Steelmaking Using Fastmet Direct Reduced Iron in the Blast Furnace

Huitu

Helle

et al. 2013

ISIJ Int.

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Steelmaking contributes by more than 5% to the world's anthropogenic CO2 emissions, so new ways to reduce the emissions in this industrial sector must be found. During a transition to more sustainable production concepts, also economic factors must be considered. In this paper the potential of using direct reduced iron (DRI) from the FASTMET process with rotary hearth furnace (RHF) technology, as a partial substitute of pellets in a blast furnace (BF) was studied. Simplified mathematical models of the different operations in a steel plant, including RHF, are combined with a more detailed model of the BF and the entire system is optimized by non-linear programming with respect to costs. The objective of the presented study is to analyze the prerequisites for an economical operation of an integrated steel plant equipped with an RHF, under different raw material prices and varying costs of CO2 emission allowances. The blast furnace operation parameters are also analyzed for different amounts of DRI charged. The results illustrate the conditions under which it would be beneficiary in a steel plant to integrate the RHF and BF technologies.

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Section: Process Modelsmentioning

confidence: 99%

Optimization of Steelmaking Using Fastmet Direct Reduced Iron in the Blast Furnace

Huitu

Helle

et al. 2013

ISIJ Int.

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“…A first-principles BF model [15][16][17] based on the fundamental concepts introduced by Rist et al 18) was used as a starting point in the modelling. The model was run under a large number of input variable values within their admissible regions (Table 1), using a feed rate of unprocessed biomass in the range to the pyrolysis unit operated within the temperature range Tpyro ∈ [150, 800]°C.…”

Section: )mentioning

confidence: 99%

Optimal Resource Allocation in Integrated Steelmaking with Biomass as Auxiliary Reductant in the Blast Furnace

2012

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An integrated steel plant with two blast furnaces with the option to use biomass to partially substitute fossil reductants was simulated. A thermodynamic blast furnace model was used, combined with simpler models of the other unit processes (sintermaking, cokemaking, basic oxygen furnace, hot stoves and power plant) and a nonlinear model of the biomass conversion with respect to the processing temperature. Given an aim steel production rate for the plant, the economics of the plant was optimized by minimizing the specific costs of liquid steel, considering costs of raw materials, energy and CO2 emissions. Limited supply of sinter and coke was optimally allocated to the two blast furnaces and the effects of restrictions in the biomass, oxygen and oil supply on the operating states were studied. An analysis was also undertaken to study how the production rate of the plant would affect the optimal state. The results demonstrate that a non-uniform distribution of the resources can be economically justified, in particular for cases where the blast furnaces operate under different constraints.

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“…Taking advantages of high productivity, high PCR (pulverized coal rate), low fuel rate, low CO 2 emission, etc., the TGR-OBF process is considered to be one of the promising ironmaking processes in future. [1][2][3][4][5][6][7][8][9][10] The exact process was presented by Wenzel in an American patent, 1) whereafter, fundamental studies such as static balance models and mathematical models were established by different researchers. [2][3][4][5][6][7][8][9][10] Meanwhile, industrial trails have been implemented in different countries to reduce carbon consumption and CO 2 emissions.…”

Section: Introductionmentioning

confidence: 99%

“…This article aims to solve the unsteady model of the TGR-OBF process, which is significant for the industrial trial but has not been reported in other papers. [2][3][4][5][6][7][8][9][10][11][12][13][14][15] …”

Section: Introductionmentioning

confidence: 99%

“…[1][2][3][4][5][6][7][8][9][10] The exact process was presented by Wenzel in an American patent, 1) whereafter, fundamental studies such as static balance models and mathematical models were established by different researchers. [2][3][4][5][6][7][8][9][10] Meanwhile, industrial trails have been implemented in different countries to reduce carbon consumption and CO 2 emissions. [11][12][13][14][15] However, after adopting high oxygen enriched blast, high pulverized coal injection (PCI) and top gas recycling system, the technical and economic indexes usually deteriorate in practice, due to the complexity of the whole systems increasing the difficulty in operation technique, and also due to lack of unsteady analyses of the TGR-OBF systems.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Unsteady Analyses of the Top Gas Recycling Oxygen Blast Furnace

Zhang

Xue

et al. 2016

ISIJ International

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An unsteady model of the top gas recycling oxygen blast furnace (TGR-OBF) process was established according to material and thermal balance principles. The restrictive kinetic step of the reaction in the bosh of oxygen blast furnace was considered, as well as the key nodes' gas recycling processes and combustion equilibrium of the shaft injection gas. Typical unsteady analyses of the TGR-OBF processes are demonstrated by the unsteady model. It is concluded that the whole TGR-OBF processes could reach equilibrium in case of reasonable operation. Based on the default conditions in this paper, it takes about 6 times for the main gas elements travelling from tuyere zone to the furnace top, until the unsteady process turns to be a stable one. The fuel rate decreases from 496 kg/t to 426 kg/t and 403 kg/t when the blast oxygen content is increased from 21.5% to 50% and 98%, and instantaneously, the top gas volume drops from 1 582 Nm 3 to 1 462 Nm 3 and 1 031 Nm 3 . Because most carbonaceous gases are deprived in the VPSA (Vacuum Pressure Swing Absorption) segment and also recycled inside of the blast furnace, the CO 2 emissions in the TGR-OBF cases are 206.06 Nm 3 and 99.56 Nm 3 /t compared to the CO 2 emission of 664.58 Nm 3 /t in the conventional blast furnace.

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Nonlinear optimization of steel production using traditional and novel blast furnace operation strategies

Cited by 52 publications

References 26 publications

Optimization of Steelmaking Using Fastmet Direct Reduced Iron in the Blast Furnace

Optimization of Steelmaking Using Fastmet Direct Reduced Iron in the Blast Furnace

Optimal Resource Allocation in Integrated Steelmaking with Biomass as Auxiliary Reductant in the Blast Furnace

Unsteady Analyses of the Top Gas Recycling Oxygen Blast Furnace

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